Decorative material

ABSTRACT

In a decorative material, a matting agent is added to, of a first gloss-adjusting layer and a second gloss-adjusting layer, one with lower gloss, where the matting agent has a particle diameter of 1.0 times or more the thickness of the gloss-adjusting layer with lower gloss. Accordingly, sufficient unevenness can be imparted to the surface of the gloss-adjusting layer; thus, glossiness does not increase in oblique observation, and low gloss can be maintained. Therefore, it is possible to provide a decorative material having a feeling of unevenness obtained by the difference in gloss that hardly changes even when observed obliquely.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a continuation application filed under 35 U.S.C. §111(a) claiming the benefit under 35 U.S.C. §§ 120 and 365(c) ofInternational Patent Application No. PCT/JP2017/019815, filed on May 26,2017, which is based upon and claims the benefit of priority to JapanesePatent Application No. 2016-105260, filed on May 26, 2016, thedisclosures of which are all hereby incorporated herein by reference intheir entireties.

TECHNICAL FIELD

The present invention relates to a decorative material for use ininterior and exterior finishes of buildings, and surface decoration offittings, furniture, etc. More specifically, the present inventionrelates to a decorative material that three-dimensionally expressesunevenness due to a difference in surface gloss.

BACKGROUND ART

Conventionally, desired design patterns, such as wood grain patterns andgrain patterns, have generally been applied to decorative materials foruse in, for example, interior and exterior finishes of buildings, andsurface decoration of fittings, furniture, etc. Moreover, decorativematerials that not only two-dimensionally express design patterns, suchas wood grain patterns and grain patterns, but also three-dimensionallyto express the feeling of unevenness of the surface of natural woodmaterials or stone materials, have also been widely used mainly forapplications for which a high-grade feeling is desired.

As a method for expressing a feeling of three-dimensional unevennesstogether with a two-dimensional design pattern on the surface ofdecorative materials, various methods have been conventionally devised,and separately used depending on the purpose. In particular, there is amethod for visually expressing three-dimensional unevenness by takingadvantage of optical illusions by changing the surface gloss state(specifically glossiness) of portions to be expressed as recesses orprojections, rather than actually forming unevenness on the surface ofthe decorative material. According to this method, even if there isactually no unevenness, the human eye recognizes portions with highergloss as projections, and portions with lower gloss as recesses.

Specifically, for example, a transparent or translucent syntheticcoating material layer with low gloss is formed on the entire printsurface of a substrate on which suitable patterns, including a recessedpattern, are printed. Then, a transparent or translucent syntheticcoating material layer with high gloss is formed on portions of thesurface of the formed synthetic coating material layer other thanportions corresponding to the recessed pattern. Of course, a decorativematerial in which the unevenness relationship is reversed can beobtained by reversing the height relationship of gloss.

This method does not require special chemicals etc., and can easilyimpart a feeling of three-dimensional unevenness to any substrates onlyby preparing two types of coating materials with different glosses. Inaddition, synthetic coating material layers with different glosses canbe formed by a known printing method, such as a gravure printing method,after the formation of a design pattern (a pattern ink layer); thus,special facilities are not required, production efficiency is high, andsynchronization with the design pattern is easy. Moreover, the thicknessof the synthetic coating material layer is much thinner than the heightdifference of unevenness to be expressed; thus, the amount of resin usedcan be reduced, there is an advantage in terms of flexibility, and adecorative material having excellent bending processability can beeasily realized. There is another advantage that contaminants do notremain in recesses because there is no large unevenness on the surfaceof the decorative material.

In consideration of these many advantages, decorative materials usingthis method have already been frequently used; however, in terms ofhigh-grade feeling, there are no methods better than methods foractually forming unevenness. The reason for this is considered to be asfollows. For example, a mechanical embossing method can faithfullyreproduce unevenness, such as natural wood vessels, including thecross-sectional shape of the vessels etc. In contrast, in this methodusing two types of coating materials with different glosses, the surfacehas two variations of glosses; thus, two variations of unevenness areexpressed. Accordingly, there is a problem that it is difficult toexpress unevenness having an inclined portion with continuously varyingdepth (height), such as natural wood vessels.

In light of the above, there have recently been proposals for decorativematerials that can express unevenness having an inclined portion, suchas natural wood vessels, by providing a synthetic coating material layerthat expresses unevenness having an inclined portion with continuouslyvarying depth (hereinafter also referred to as a “gloss-adjustinglayer”) (see, for example, PTL 1).

CITATION LIST Patent Literature

PTL 1: JP 3629964 B

SUMMARY OF THE INVENTION Technical Problem

Here, as a general method for adjusting the gloss of the gloss-adjustinglayer, a gloss-adjusting agent (a matting agent) is added to atransparent resin, which is used as a binder. Fine particles of aninorganic material or organic material are mainly used asgloss-adjusting agents. In particular, inorganic material fine particles(particularly silica fine particles) have high matting ability and arewidely used. Due to the addition of a gloss-adjusting agent, thegloss-adjusting agent imparts unevenness to the surface of thegloss-adjusting layer, and light is scattered on the uneven surface,thereby obtaining a matting effect. Desired gloss can be freely obtainedby controlling the type and amount of such a gloss-adjusting agent.

However, unevenness imparted by a gloss-adjusting agent is smaller thanthe thickness of the gloss-adjusting layer, and much smaller thanunevenness imparted by a mechanical embossing method. Therefore,although a sufficient feeling of unevenness due to a difference in glossis obtained when the decorative material surface is observed from thefront, the glossiness of a portion with lower gloss increases when thedecorative material surface is observed obliquely. This causes a problemthat the feeling of unevenness obtained by a difference in gloss isreduced. When decorative materials are actually used for interior andexterior finishes of buildings, or for fittings, furniture, etc., usersare found to observe the decorative material surface from variousangles. Accordingly, there is a problem that the feeling of unevennesshas angular dependence as described above and this thereby significantlyimpairs the high-grade feeling of the decorative materials.

In order to solve the above problems, an object of the present inventionis to provide a decorative material having a feeling of unevennessobtained by a difference in gloss that hardly changes even when observedobliquely.

Solution to Problem

As a result of extensive research, the present inventors found that whenthe thickness of a gloss-adjusting layer with lower gloss and theparticle diameter of a matting agent to be added were set within anoptimal range, the gloss increase of the gloss-adjusting layer whenobserved obliquely could be suppressed, and the feeling of unevennessdue to the difference in gloss was not impaired even when observed fromvarious angles.

In order to achieve the above object, the decorative material of oneembodiment of the present invention comprises a first gloss-adjustinglayer provided on a substrate, and a second gloss-adjusting layerpartially provided on the first gloss-adjusting layer, and having glossthat is different from that of the first gloss-adjusting layer;characterized in that a matting agent is added to, of the firstgloss-adjusting layer and the second gloss-adjusting layer (i.e., eitherto first gloss-adjusting layer or to the second gloss-adjusting layer),one with lower gloss, where the matting agent has a particle diameter of1.0 times or more the thickness of the gloss-adjusting layer havinglower gloss.

Advantageous Effects of the Invention

According to the decorative material of one embodiment of the presentinvention, when the layer thickness of a gloss-adjusting layer withlower gloss and the particle diameter of a matting agent to be added areset within the optimal range, the gloss increase of the gloss-adjustinglayer when observed obliquely can be suppressed, and it is possible toprovide a decorative material having a feeling of unevenness obtained bythe difference in gloss that hardly changes even when observedobliquely.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view showing a decorative material.

FIG. 2 is a cross-sectional view showing a modification of thedecorative material.

DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

A decorative material 1 according to an embodiment of the presentinvention is described with reference to the drawings. With reference tothe drawings, an embodiment of the present invention will be describedin detail. It is to be understood that the present invention is notlimited to the following embodiment, which is intended to berepresentative of the present invention. The representative embodimentdescribed below is merely an example of the present invention, and thedesign thereof could be appropriately changed by one skilled in the art.Incidentally, unless there is a reason for the sake of convenience, thesame reference signs will be used for identical components, andredundant explanations will be omitted. It will be noted that in thedrawings, like or corresponding parts are designated by like referencenumerals and redundant illustrations therefor are omitted. Thedimensional ratios in the drawings should not be construed as limited tothose ratios shown therein. Here, the drawings are schematic, and therelationship between thickness and plane size, the ratio of thethickness of each layer, etc., are different from actual ones. Thetechnical idea of the present invention can be modified in various wayswithin the technical scope specified by the claims

(Structure)

As shown in FIG. 1, the decorative material 1 of the present embodimentcomprises a first gloss-adjusting layer 5 provided on a substrate 2, anda second gloss-adjusting layer 6 partially provided on the firstgloss-adjusting layer 5, and having gloss different from that of thefirst gloss-adjusting layer 5. It is important that a matting agent beadded to, of these first and second gloss-adjusting layers 5 and 6, theone with lower gloss, where the matting agent has a particle diameter of1.0 times or more, and preferably 1.1 times or more, the thickness ofthe gloss-adjusting layer having lower gloss. Because sufficientunevenness can be thereby imparted to the surface of the gloss-adjustinglayer, glossiness does not increase in oblique observation, and lowgloss can be maintained.

Other layers, such as a base ink layer 3, a pattern ink layer 4, and atransparent resin layer (not shown), may be disposed between thesubstrate 2 and the first gloss-adjusting layers 5, as described later.The base ink layer 3 may be formed, for example, by application of inkover an entire surface of the substrate 2.

The layer thickness mentioned herein refers to the thickness of a resinpart that fills between the matting agents when the cross section of thegloss-adjusting layer with lower gloss is observed. In the presentembodiment, the particle diameter of the matting agent is 1.1 times ormore the layer thickness; thus, the matting agent is not buried in thegloss-adjusting layer, and is partially exposed from the surface.Therefore, the layer thickness can be determined by measuring the heightof the several resin parts between the matting agents, and averaging theobtained values. Regarding the particle diameter, when the particleshape is not spherical, the cross-sectional shape of the particles maybe regarded as elliptical, and the average of the major axis and minoraxis may be used as the particle diameter. That is, the particlediameter in the present embodiment refers to an average particlediameter when the particles are assumed to have a circular or ellipticalcross-sectional shape.

Although the present embodiment describes a case in which the particlediameter of the matting agent is 1.1 times or more the layer thickness,the present embodiment is not limited thereto. For example, even whenthe particle diameter of the matting agent is 1.0 times the layerthickness, the matting agent is not buried in the gloss-adjusting layer,and is partially exposed from the surface. This is because some mattingagents, described later, have surfaces with low “wettability” for theresin that forms the gloss-adjusting layer. In that case, the resin isrepelled on part of the surface of the matting agent during theformation of the gloss-adjusting layer.

Moreover, the upper limit of the particle diameter of the matting agentis preferably 3.0 times the thickness of the gloss-adjusting layer withlower gloss, considering that a larger particle diameter tends to causeremoval from the resin component, so that abrasion resistance andscratch resistance required for decorative materials are deteriorated;and that a larger particle diameter increases surface unevenness, sothat contaminant component-wiping properties are worsened to therebycause deterioration of contamination resistance.

Regarding the relationship between the layer thickness and the particlediameter of the matting agent, it is important that the particlediameter of the matting agent be 1.0 times or more, and preferably 1.1times or more, the layer thickness; however, the specific size may beany numerical value. For example, when the layer thickness is 5 μm, theparticle diameter of the matting agent may be 5.0 μm or more, and morepreferably 5.5 μm or more.

As the matting agent, a commercially available known matting agent canbe used. For example, fine particles of an inorganic material, such assilica, glass, alumina, calcium carbonate, barium sulfate, or acrylic,can be used. Because the first and second gloss-adjusting layers 5 and 6are required to have high transparency, it is particularly preferable touse fine particles of silica, glass, or acrylic, which have hightransparency. In particular, among silica fine particles, a mattingagent with a low bulk density in which fine primary particles undergosecondary aggregation has a higher matting effect relative to theaddition amount, than solid spherical particles. Thus, a gloss-adjustinglayer with lower gloss can be formed using such a matting agent.Accordingly, the difference in gloss between the first gloss-adjustinglayer 5 and the second gloss-adjusting layer 6 can be increased, and thefeeling of unevenness to be obtained can be enhanced. An excellentdesign expression of greater depth can be thereby achieved.

The particle diameter of the matting agent can be any numerical value,as described above; however, when a known matting agent is used, theparticle diameter thereof is preferably 2 μm or more and 15 μm or less.The particle diameter is more preferably 4 μm or more and 12 μm or less.Because a matting agent having a particle diameter of less than 2 μm hasa low matting effect, a feeling of unevenness, which is a feature of thepresent embodiment, cannot be sufficiently obtained. Moreover, a mattingagent having a particle diameter of larger than 15 μm leads to stronglight scattering, which causes cloudiness of the first and secondgloss-adjusting layers 5 and 6, increases visual particle recognition,and impairs the feeling of unevenness, this unevenness being a featureof the present embodiment.

Examples of the resin part (resin composition) that constitutes thefirst and second gloss-adjusting layers 5 and 6 includepolyurethane-based resins, acrylic silicon-based resins, fluorine-basedresins, epoxy-based resins, vinyl-based resins, polyester-based resins,melamine-based resins, amino-alkyd-based resins, urea-based resins, andthe like. Moreover, the resin composition may be in the form of anaqueous solution, an emulsion, a solvent, or the like, and the form ofthe resin composition is not limited. Furthermore, as the method forcuring the resin composition, for example, a one-component curing agentor a two-component curing agent, or an ultraviolet curing method, can beused.

In the present embodiment, the resin composition is particularlypreferably a urethane-based resin using isocyanate in terms ofworkability, price, cohesive force of the resin itself, etc. Usableexamples of the isocyanate include curing agents, such as adductproducts, biuret products, and isocyanurate products, which arederivatives of tolylene diisocyanate (TDI), xylylene diisocyanate (XDI),hexamethylene diisocyanate (HMDI), diphenylmethane diisocyanate (MDI),lysine diisocyanate (LDI), isophorone diisocyanate (IPDI), methylhexanediisocyanate (HTDI), bis(isocyanatomethyl)cyclohexane (HXDI),trimethylhexamethylene diisocyanate (TMDI), etc.

Among these, for applications for which weather resistance is required,it is preferable to use hexamethylene diisocyanate (HMDI) having alinear molecular structure. For applications for which surface hardnessis required, it is preferable to use isophorone diisocyanate (IPDI).Furthermore, it is also effective to use a mixture of hexamethylenediisocyanate (HMDI) and isophorone diisocyanate (IPDI) in order tocombine their advantages. In addition, in order to improve surfacehardness, it is preferable to use a resin that can be cured by activeenergy rays, such as ultraviolet rays or electron rays. These resins canbe used in combination with each other.

Furthermore, in order to impart various functions, for example,functional additives, such as an antimicrobial agent and an antifungalagent, may be added to the first and second gloss-adjusting layers 5 and6. Moreover, an ultraviolet absorber and a light stabilizer may beadded, if necessary. Usable examples of ultraviolet absorbers includebenzotriazole-based ultraviolet absorbers, benzoate-based ultravioletabsorbers, benzophenone-based ultraviolet absorbers, and triazine-basedultraviolet absorbers. Moreover, usable examples of light stabilizersinclude hindered amine-based light stabilizers. Furthermore, whencontamination control performance and Sellotape (registered trademark)mold-release characteristics are required, a release agent having asilicone skeleton can be added. In this case, the type of release agentis not limited; however, the use of a silicone release agent having anend functional group that is reactive with the resin composition canimprove contamination control performance and the durability ofSellotape mold-release characteristics.

In the present embodiment, the first and second gloss-adjusting layers 5and 6 have different glosses. Moreover, the first gloss-adjusting layer5 covers the entire surface of the substrate 2 on the firstgloss-adjusting layer 5 side, and the second gloss-adjusting layer 6partially covers the surface of the first gloss-adjusting layer 5 on thesecond gloss-adjusting layer 6 side. Unevenness is expressed by thedifference in gloss between the first and second gloss-adjusting layers5 and 6.

The present embodiment shows an example in which the firstgloss-adjusting layer 5 covers the entire surface of the substrate 2 onthe first gloss-adjusting layer 5 side; however, other structures mayalso be employed. For example, the first gloss-adjusting layer 5 may beconfigured to partially cover the surface of the substrate 2 on thefirst gloss-adjusting layer 5 side.

Moreover, a matting agent is added to, of the first and secondgloss-adjusting layers 5 and 6, one with lower gloss. The amount of thematting agent added is preferably 5 parts by mass or more and 40 partsby mass or less relative to 100 parts by mass of the resin composition.The amount of the matting agent added is more preferably 10 parts bymass or more and 30 parts by mass or less. If the amount of the mattingagent is less than 5 parts by mass, the matting effect is insufficient;thus, the gloss difference from the gloss-adjusting layer with highergloss is reduced, so that the feeling of unevenness is insufficient. Incontrast, if the amount of the matting agent is larger than 40 parts bymass, the resin composition is relatively insufficient with respect tothe matting agent, thereby resulting in the removal of the mattingagent, and reduction in scratch resistance due to the removal of thematting agent, so that the durability required for the decorativematerial 1 is severely impaired.

It is also possible to add any matting agent to the gloss-adjustinglayer with higher gloss. These should be suitably adjusted according tothe final feeling of unevenness and designability. The matting agent andthe resin composition used in the first and second gloss-adjustinglayers 5 and 6 may be the same or different. These can be freelyselected depending on the feeling of unevenness and variouscharacteristics demanded.

The thickness of the first and second gloss-adjusting layers 5 and 6 maybe any numerical value; however, because the particle diameter of thematting agent is preferably 2 μm or more and 15 μm or less, as describedabove, the thickness of the first and second gloss-adjusting layers 5and 6 is preferably within an equivalent range, and more preferably 1.8μm or more and 13.6 μm or less. Moreover, the first and secondgloss-adjusting layers 5 and 6 are layers on the outermost surface ofthe decorative material 1, and are thus required to have surfacephysical properties, such as abrasion resistance, scratch resistance,solvent resistance, and contamination resistance, which are required forthe decorative material 1. Of these properties, abrasion resistance andscratch resistance are influenced by the layer thickness, and a higherlayer thickness is advantageous. Therefore, the thickness of the firstand second gloss-adjusting layers 5 and 6 is more preferably 2 μm ormore and 12 μm or less. If the layer thickness is less than 1.8 μm,abrasion resistance and scratch resistance are significantly reduced;thus, the use as the decorative material 1 may be limited. In contrast,if the layer thickness is larger than 13.6 μm, the flexibility of thefirst and second gloss-adjusting layers 5 and 6 themselves is reduced;thus, the processability as the decorative material 1 may bedeteriorated.

The substrate 2 is not limited, as long as it is usable as base paperfor the decorative material 1. Examples thereof include paper, such astissue paper, resin-mixed paper, titanium paper, resin-impregnatedpaper, flame-resistant paper, and inorganic paper; woven fabrics ornon-woven fabrics made of natural fibers or synthetic fibers; syntheticresin-based substrates comprising homo or random polypropylene resins,polyolefin resins such as polyethylene resin, copolymerized polyesterresins, crystalline polyester resins in an amorphous state, polyethylenenaphthalate resins, polybutylene resins, acrylic resins, polyamideresins, polycarbonate resins, polyvinyl chloride resins, polyvinylidenechloride resins, fluororesins, etc.; wooden substrates, such as woodveneer, sliced veneer, plywood, laminate lumber, particle board, andmedium density fiberboard; inorganic substrates, such as gypsum plates,cement plates, calcium silicate plates, and pottery plates; metal-basedsubstrates, such as iron, copper, aluminum, and stainless steel;composite materials and laminates thereof; and other conventionallyknown materials. Moreover, the shape of the substrate 2 can be, forexample, a film shape, a sheet shape, a plate shape, a profile moldedarticle, or the like.

A pattern ink layer 4 for adding a design pattern to the decorativematerial 1 can be formed between the substrate 2 and the firstgloss-adjusting layers 5. Usable examples of the design pattern includewood grain patterns, grain patterns, sand patterns, tiling patterns,brick patterns, fabric patterns, grain leather patterns, geometricpatterns, and the like. In the example of FIG. 1, the pattern ink layer4 is formed in a portion directly below the second gloss-adjusting layer6. In other words, the second gloss-adjusting layer 6 is formed only ina portion overlapping the pattern ink layer 4. Moreover, the designpattern of the pattern ink layer 4 is synchronized with the gloss of thesecond gloss-adjusting layer 6. The designability due to the secondgloss-adjusting layer 6 can be thereby added to the designability due tothe pattern ink layer 4. Therefore, it is possible to form a decorativematerial 1 having a high-grade design expression close to natural woodor natural stone.

The present embodiment shows an example in which the secondgloss-adjusting layer 6 is formed only in a portion overlapping thepattern ink layer 4, that is, the second gloss-adjusting layer 6 isformed only in a portion directly above the pattern ink layer 4;however, other structures can also be employed. For example, the secondgloss-adjusting layer 6 may be formed in a portion overlapping thepattern ink layer 4; in addition to the portion directly above thepattern ink layer 4, the second gloss-adjusting layer 6 may be formed inpartial portions other than the right above portion.

Furthermore, a base ink layer 3, which covers the entire surface of thesubstrate 2 on the first gloss-adjusting layer 5 side, may be formedbetween the substrate 2 and the pattern ink layer 4, depending on thedesired design. Moreover, the base ink layer 3 may be a multilayer oftwo or more layers, if necessary, to achieve masking properties etc.Furthermore, the pattern ink layer 4 may be formed by laminating as manylayers as necessary for expression of the desired design. Thus, thepattern ink layer 4 and the base ink layer 3 can be combined in variousways depending on the desired design, i.e., design to be expressed;however, they are not limited.

The constituent materials of the base ink layer 3 and the pattern inklayer 4 are not limited. For example, printing ink in which a matrix anda coloring agent, such as dye or pigment, are dissolved and dispersed ina solvent, or a coating agent, can be used. Examples of the matrixinclude various synthetic resins, such as oily nitrocellulose resin,two-component urethane resin, acrylic-based resin, styrene-based resin,polyester-based resin, urethane-based resin, polyvinyl-based resin,alkyd resin, epoxy-based resin, melamine-based resin, fluororesin,silicone-based resin, and rubber-based resin; mixtures thereof,copolymers thereof, etc. Further, examples of the coloring agent includeinorganic pigments, such as carbon black, titanium white, zinc white,rouge, chrome yellow, Prussian blue, and cadmium red; organic pigments,such as azo pigments, lake pigments, anthraquinone pigments,phthalocyanine pigments, isoindolinone pigments, and dioxazine pigments;and mixtures thereof. Moreover, usable examples of the solvent includetoluene, xylene, ethyl acetate, butyl acetate, methyl alcohol, ethylalcohol, isopropyl alcohol, acetone, methyl ethyl ketone, methylisobutyl ketone, cyclohexanone, water, and mixtures thereof.

Further, in order to impart various functions, for example, functionaladditives, such as an extender pigment, a plasticizer, a dispersant, asurfactant, a tackifier, an adhesive aid, a drying agent, a curingagent, a curing accelerator, and a curing retarder, may be added to thebase ink layer 3 and the pattern ink layer 4.

Each of the base ink layer 3, the pattern ink layer 4, and the first andsecond gloss-adjusting layers 5 and 6 can be formed, for example, byvarious printing methods, such as a gravure printing method, an offsetprinting method, a screen printing method, an electrostatic printingmethod, and an ink-jet printing method. Moreover, because the base inklayer 3 and the first gloss-adjusting layer 5 cover the entire surfaceof the substrate 2 on the first gloss-adjusting layer 5 side, they canbe formed, for example, by various coating methods, such as a rollcoating method, a knife coating method, a microgravure coating method,and a die coating method. These printing methods and coating methods maybe selected separately depending on the layer to be formed, or the samemethod may be selected to carry out combined processing.

In order to adjust the thickness of the first and the secondgloss-adjusting layers 5 and 6, the coating amount may be adjusted inthe above printing methods and coating methods. The coating amount canbe calculated by producing a product in which a gloss-adjusting layer isformed on the substrate 2, and a product in which a gloss-adjustinglayer is not formed in the various printing methods and coating methods,and determining the coating amount from their mass difference. Therelationship between coating amount and thickness can be determined bycross-sectional observation.

In particular, when abrasion resistance is required, a transparent resinlayer (not shown) can be provided between the pattern ink layer 4 andthe first gloss-adjusting layer 5. As the transparent resin layer, forexample, a resin composition comprising an olefin-based resin as a maincomponent is preferably used. Examples of the olefin-based resin includepolypropylene, polyethylene, and polybutene; as well as those obtainedby homopolymerization or copolymerization of two or more α-olefins(e.g., propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene,1-nonene, 1-decene, 1-undecene, 1-dodecene, tridecene, 1-tetradecene,1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene,1-eicosene, 3-methyl-1-butene, 3-methyl-1-pentene, 3-ethyl-1-pentene,4-methyl-1-pentene, 4-methyl-1-hexene, 4,4-dimethyl-1-pentene,4-ethyl-1-hexene, 3-ethyl-1-hexene, 9-methyl-1-decene,11-methyl-1-dodecene, and 12-ethyl-1-tetradecene); and those obtained bycopolymerization of ethylene or α-olefins with other monomers, such asan ethylene-vinyl acetate copolymer, an ethylene-vinyl alcoholcopolymer, an ethylene-methyl methacrylate copolymer, an ethylene-ethylmethacrylate copolymer, an ethylene-butyl methacrylate copolymer, anethylene-methyl acrylate copolymer, an ethylene-ethyl acrylatecopolymer, and an ethylene-butyl acrylate copolymer. In particular, inorder to further improve surface strength, highly crystallinepolypropylene is preferably used.

Furthermore, the transparent resin layer may contain, for example,additives, such as a heat stabilizer, an ultraviolet absorber, a lightstabilizer, an antiblocking agent, a catalyst scavenger, and a coloringagent. These additives can be suitably selected from known additives.Moreover, the transparent resin layer can be formed, for example, byvarious lamination methods, such as a method using thermal pressure, anextrusion lamination method, and a dry lamination method.

(Effects and Others)

(1) As described above, in the decorative material 1 of the presentembodiment, a matting agent is added to, of the first gloss-adjustinglayer 5 and the second gloss-adjusting layer 6, one with lower gloss,where the matting agent has a particle diameter of 1.0 times or more,and more preferably 1.1 times or more, the thickness of thegloss-adjusting layer with lower gloss. Accordingly, sufficientunevenness can be imparted to the surface of the gloss-adjusting layer;thus, glossiness does not increase in oblique observation, and low glosscan be maintained. Therefore, it is possible to provide a decorativematerial 1 having a feeling of unevenness obtained by the difference ingloss that hardly changes even when observed obliquely.

(2) Moreover, in the decorative material 1 of the present embodiment,the design pattern of the pattern ink layer 4 is synchronized with thegloss of the second gloss-adjusting layer 6; thus, the designability dueto the second gloss-adjusting layer 6 can be added to the designabilitydue to the pattern ink layer 4, so that a decorative material 1 having ahigh-grade design expression close to natural wood or natural stone canbe formed.

(3) Furthermore, in the decorative material 1 of the present embodiment,a matting agent comprising an inorganic material having a high mattingeffect is used. Therefore, the gloss of the gloss-adjusting layer towhich the matting agent is added can be significantly reduced.Accordingly, the difference between the gloss of the firstgloss-adjusting layer 5 and the gloss of the second gloss-adjustinglayer 6 can be increased, and the feeling of unevenness obtained can beenhanced. An excellent design expression of greater depth can be therebyachieved.

(4) Furthermore, in the decorative material 1 of the present embodiment,the matting agent is added in an amount of 5 parts by mass or more and40 parts by mass or less relative to 100 parts by mass of a resincomposition that constitutes the gloss-adjusting layer with lower gloss.Accordingly, sufficient unevenness can be reliably imparted to thesurface of the gloss-adjusting layer; thus, glossiness does not increasein oblique observation, and low gloss can be reliably maintained.Therefore, it is possible to reliably provide a decorative material 1having a feeling of unevenness obtained by the difference in gloss thathardly changes even when observed obliquely.

(5) Furthermore, in the decorative material 1 of the present embodiment,the matting agent is also added to the gloss-adjusting layer with highergloss. Even in such an embodiment, sufficient unevenness can be impartedto the surface of the gloss-adjusting layer; thus, glossiness does notincrease in oblique observation, and low gloss can be maintained.Therefore, it is possible to provide a decorative material 1 having afeeling of unevenness obtained by the difference in gloss that hardlychanges even when observed obliquely.

(6) Furthermore, in the decorative material 1 of the present embodiment,the particle diameter of the matting agent is 2 μm or more and 15 μm orless. Therefore, a feeling of unevenness on the surface of thegloss-adjusting layer can be sufficiently obtained.

(7) Furthermore, in the decorative material 1 of the present embodiment,the particle diameter of the matting agent is 3.0 or less times thethickness of the gloss-adjusting layer with lower gloss. Accordingly,the removal of the matting agent can be suppressed; thus, it is possibleto provide a decorative material 1 having excellent abrasion resistanceand scratch resistance, as well as excellent contaminantcomponent-wiping properties.

(Modification)

The present embodiment shows an example in which the secondgloss-adjusting layer 6 is formed in a portion overlapping the patternink layer 4, and the design pattern of the pattern ink layer 4 issynchronized with the gloss of the second gloss-adjusting layer 6;however, other structures can also be employed. For example, as shown inFIG. 2, the second gloss-adjusting layer 6 may be formed in a portionother than directly above the pattern ink layer 4, and the designpattern of the pattern ink layer 4 may be synchronized with the gloss ofthe first gloss-adjusting layer 5. The gloss of the exposed firstgloss-adjusting layer 5 is thereby imparted to the design pattern of thepattern ink layer 4, so that the designability due to the firstgloss-adjusting layer 5 can be added to the designability due to thepattern ink layer 4. Therefore, it is possible to form a decorativematerial 1 having a high-grade design expression close to natural woodor natural stone.

Specific Examples of the decorative material 1 according to the presentembodiment are described below.

Example 1

In Example 1, impregnated paper having a basis weight of 50 g/m²(GFR-506, produced by Kohjin Co., Ltd.) was used as a substrate 2. Then,a base ink layer 3 and a pattern ink layer 4 were formed in this orderon one side of the substrate 2 using oily nitrocellulose resin gravureprinting ink (each color of PCNT (PCRNT), produced by Toyo Ink Co.,Ltd.). The design pattern of the pattern ink layer 4 was a wood grainpattern.

Subsequently, ink for a first gloss-adjusting layer 5 was applied to thesubstrate 2, on which the pattern ink layer 4 was formed, so as to coverthe entire surface of one side of the substrate 2, thereby forming thefirst gloss-adjusting layer 5. The ink was composed of 8 parts by massof silica-based matting agent (Mizukasil 310P, produced by Fuji SilysiaChemical Ltd.) and 10 parts by mass of polyisocyanate (UR190B curingagent, produced by Toyo Ink Co., Ltd.) relative to 100 parts by mass ofacrylic polyol (6KW-700, produced by Taisei Fine Chemical Co., Ltd.).The coating amount of the ink was 2.5 g/m². The thickness obtained bycross-sectional observation was 2.1 μm. The average particle diameter ofthe silica-based matting agent was 2.7 μm. Next, ink for a secondgloss-adjusting layer 6 was applied to a portion of the firstgloss-adjusting layer 5 directly above the pattern ink layer 4, therebyforming the second gloss-adjusting layer 6. The ink was composed of 3parts by mass of silica-based matting agent (Mizukasil 310P, produced byFuji Silysia Chemical Ltd.) and 10 parts by mass of polyisocyanate(UR190B curing agent, produced by Toyo Ink Co., Ltd.) relative to 100parts by mass of acrylic polyol (6KW-700, produced by Taisei FineChemical Co., Ltd.). The average particle diameter of the silica-basedmatting agent was 2.7 μm.

Example 2

In Example 2, ink for a first gloss-adjusting layer 5 was applied to asubstrate 2, on which a pattern ink layer 4 was formed, so as to coverthe entire surface of one side of the substrate 2, thereby forming thefirst gloss-adjusting layer 5. The ink was composed of 8 parts by massof silica-based matting agent (ACEMATT OK900, produced by Evonik JapanCo., Ltd.) and 10 parts by mass of polyisocyanate (UR190B curing agent,produced by Toyo Ink Co., Ltd.) relative to 100 parts by mass of acrylicpolyol (6KW-700, produced by Taisei Fine Chemical Co., Ltd.). Theaverage particle diameter of the silica-based matting agent was 7.5 μm.Moreover, the coating amount of the ink was 7 g/m². The thicknessobtained by cross-sectional observation was 6.5 μm. Next, ink for asecond gloss-adjusting layer 6 was applied to only a portion of thefirst gloss-adjusting layer 5 directly above the pattern ink layer 4,thereby forming the second gloss-adjusting layer 6. The ink was composedof 3 parts by mass of silica-based matting agent having an averageparticle diameter of 7.5 μm (ACEMATT OK900, produced by Evonik JapanCo., Ltd.) and 10 parts by mass of polyisocyanate (UR190B curing agent,produced by Toyo Ink Co., Ltd.) relative to 100 parts by mass of acrylicpolyol (6KW-700, produced by Taisei Fine Chemical Co., Ltd.). Otherconfigurations were the same as those of Example 1.

Example 3

In Example 3, ink for a first gloss-adjusting layer 5 was applied to asubstrate 2, on which a pattern ink layer 4 was formed, so as to coverthe entire surface of one side of the substrate 2, thereby forming thefirst gloss-adjusting layer 5. The ink was composed of 8 parts by massof silica-based matting agent (ACEMATT 810, produced by Evonik JapanCo., Ltd.) and 10 parts by mass of polyisocyanate (UR190B curing agent,produced by Toyo Ink Co., Ltd.) relative to 100 parts by mass of acrylicpolyol (6KW-700, produced by Taisei Fine Chemical Co., Ltd.). Theaverage particle diameter of the silica-based matting agent was 10.5 μm.Moreover, the coating amount of the ink was 9.5 g/m². The thicknessobtained by cross-sectional observation was 9.3 μm. Next, ink for asecond gloss-adjusting layer 6 was applied to only a portion of thefirst gloss-adjusting layer 5 directly above the pattern ink layer 4,thereby forming the second gloss-adjusting layer 6. The ink was composedof 3 parts by mass of silica-based matting agent having an averageparticle diameter of 10.5 μm (ACEMATT 810, produced by Evonik Japan Co.,Ltd.) and 10 parts by mass of polyisocyanate (UR190B curing agent,produced by Toyo Ink Co., Ltd.) relative to 100 parts by mass of acrylicpolyol (6KW-700, produced by Taisei Fine Chemical Co., Ltd.). Otherconfigurations were the same as those of Example 1.

Comparative Example 1

In Comparative Example 1, ink for a first gloss-adjusting layer 5 of thesame composition as that of Example 1 was applied to a substrate 2, onwhich a pattern ink layer 4 was formed, in a coating amount of 3.5 g/m²so as to cover the entire surface of one side of the substrate 2. Exceptfor the above, a first gloss-adjusting layer 5 and a secondgloss-adjusting layer 6 were formed in the same manner as in Example 1,thereby obtaining a decorative material 1. In this case, the thicknessof the first gloss-adjusting layer 5 obtained by cross-sectionalobservation was 3.3 μm.

Comparative Example 2

In Comparative Example 2, ink for a first gloss-adjusting layer 5 of thesame composition as that of Example 2 was applied to a substrate 2, onwhich a pattern ink layer 4 was formed, in a coating amount of 8.5 g/m²so as to cover the entire surface of one side of the substrate 2. Exceptfor the above, a first gloss-adjusting layer 5 and a secondgloss-adjusting layer 6 were formed in the same manner as in Example 2,thereby obtaining a decorative material 1. In this case, the thicknessof the first gloss-adjusting layer 5 obtained by cross-sectionalobservation was 8.4 μm.

Comparative Example 3

In Comparative Example 3, ink for a first gloss-adjusting layer 5 of thesame composition as that of Example 3 was applied to a substrate 2, onwhich a pattern ink layer 4 was formed, in a coating amount of 11.5 g/m²so as to cover the entire surface of one side of the substrate 2. Exceptfor the above, a first gloss-adjusting layer 5 and a secondgloss-adjusting layer 6 were formed in the same manner as in Example 3,thereby obtaining a decorative material 1. In this case, the thicknessof the first gloss-adjusting layer 5 obtained by cross-sectionalobservation was 11.2 μm.

<Evaluation>

Examples 1 to 3 and Comparative Examples 1 to 3 above were evaluated fordesignability and glossiness.

<Designability>

The designability of each decorative material 1 was observed from thefront and obliquely. When a feeling of unevenness was recognized fromvarious angles, this case was evaluated as “++”; when a feeling ofunevenness was reduced in oblique observation, this case was evaluatedas “+”; and when a feeling of unevenness was not recognized in obliqueobservation, this case was evaluated as “−.”

<Glossiness>

The glossiness at 20°, 60°, and 85° was measured in the firstgloss-adjusting layer 5, i.e., the gloss-adjusting layer with lowergloss.

Table 1 shows these evaluation results.

TABLE 1 Glossiness Item Designability 20° 60° 85° Example 1 ++ 0.5 1.01.8 Example 2 ++ 0.5 0.9 1.6 Example 3 ++ 0.6 0.9 1.5 Comparative − 0.51.2 9.8 Example 1 Comparative − 0.5 1.1 9.4 Example 2 Comparative + 0.61.0 7.0 Example 3

It is found that in the decorative materials 1 of Examples 1 to 3, afeeling of unevenness is maintained even when they are observedobliquely, as shown in Table 1. On the other hand, in the decorativematerials 1 of Comparative Examples 1 to 3, a feeling of unevenness isreduced or not recognized when they are observed obliquely. Thistendency also appears in the measurement results of glossiness. It isconsidered that in Comparative Examples 1 to 3, the glossiness (gloss)at 85°, which corresponded to oblique observation, increased, and thatthe difference between the glossiness (gloss) of the firstgloss-adjusting layer 5 and the glossiness (gloss) of the secondgloss-adjusting layer 6 was reduced, so that the feeling of unevennessobtained by the difference in gloss was reduced.

The above results revealed that the decorative materials 1 of Examples 1to 3 had excellent design in which a feeling of unevenness obtained bythe difference in gloss was constant even when observed from variousangles.

The decorative material of the present invention is not limited to theabove embodiments and Examples, and various modifications can be madewithin a range that does not impair the features of the invention.

REFERENCE SIGNS LIST

1 . . . Decorative material; 2 . . . Substrate; 3 . . . Base ink layer;4 . . . Pattern ink layer; 5 . . . First gloss-adjusting layer; 6 . . .Second gloss-adjusting layer.

What is claimed is:
 1. A decorative material comprising: a firstgloss-adjusting layer provided on a substrate, and a secondgloss-adjusting layer partially provided on the first gloss-adjustinglayer, and having gloss that is different from that of the firstgloss-adjusting layer; wherein a matting agent is added to, of the firstgloss-adjusting layer and the second gloss-adjusting layer, one withlower gloss, where the matting agent is a silica mating agent having aparticle diameter of 1.1 times and 1.3 times a thickness of thegloss-adjusting layer with lower gloss, wherein the particle diameter ofthe silica mating agent is from 2 μm to 12 μm; wherein an amount of thesilica mating agent in the gloss-adjusting layer with lower gloss isfrom 5 parts by mass to 30 parts to 100 parts of a resin compositionthat constitutes the gloss-adjusting layer with lower gloss; wherein thematting agent is also added to the gloss-adjusting layer with highergloss; wherein an amount of the mating agent in the gloss-adjustinglayer with higher gloss is about 3 mass parts per 100 parts of a resincomposition of a resin composition that constitutes the gloss-adjustinglayer with higher gloss, wherein the amount of the silica mating agentin the gloss-adjusting layer with lower gloss is from 5 parts by mass to10 parts to 100 parts of the resin composition that constitutes thegloss-adjusting layer with lower gloss and wherein an 85° glossiness ofthe decorative material is 1.8 or less.
 2. The decorative material ofclaim 1, wherein the decorative material further comprises a pattern inklayer provided between the substrate and the first gloss-adjustinglayer; the second gloss-adjusting layer is formed in a portionoverlapping the pattern ink layer; and a design pattern of the patternink layer is synchronized with the gloss of the second gloss-adjustinglayer.
 3. The decorative material of claim 1, wherein the decorativematerial further comprises a pattern ink layer provided between thesubstrate and the first gloss-adjusting layer; the first gloss-adjustinglayer entirely covers a surface of the substrate on a firstgloss-adjusting layer side; the second gloss-adjusting layer is formedin a portion other than a portion directly above the pattern ink layer;and the design pattern of the pattern ink layer is synchronized with thegloss of the first gloss-adjusting layer.
 4. The decorative material ofclaim 1, wherein the first gloss-adjusting layer is the gloss-adjustinglayer with the lower gloss.
 5. The decorative material of claim 1,wherein the first gloss-adjusting layer is the gloss-adjusting layerwith the lower gloss.